Rockler GRP41444 Operating instructions

Brand: Rockler

Model: GRP41444

Type: Operating instructions

Rockler GRP41444 Butt Hinge Mortise Template is designed to work with the JIG IT Hinge Mortising System (sold separately) to create precise mortises for installing butt hinges. It features laser-etched markings for accurate alignment and can be used with a variety of hinge sizes. The template is compatible with 3/16" straight router bits and 3/8" O.D. guide bushing and locking nut (all sold separately). With this template, you can easily create mortises that are flush or slightly proud of the surface, ensuring a professional-looking finish for your woodworking projects.

Review full instructions prior to use for important safety information.

Always check Rockler.com to confirm that you are using the most recent version of instructions for your product.

Butt Hinge Mortise Template Instructions

Effective Octrober 2022

2BP0222

GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any

manner not described in these instructions. Use only recommended accessories. Before using the Butt Hinge Mortise Templates:

READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY

AVAILABLE FOR FUTURE REFERENCE.

> Always confirm that you are using the most recent version of

the Instructions and safety warnings for your product (see the

Instructions link on the product page at Rockler.com).

> Before using another tool with this product, always read,

understand and follow the instructions and safety warnings

in the owner’s manual for that tool. If you do not have the

owner’s manual, obtain one from the tool’s manufacturer

before using it with this product.

> Before using any chemical with this product, always read,

understand and follow all safety warnings and guidelines in

the manufacturer’s Safety Data Sheet (SDS; formerly called

“MSDS”), especially regarding:

• How to safely use the chemical, including potential hazards

and recommended first aid measures;

• Personal safety equipment required to safely use the

chemical (e.g. gloves, eye protection, mask/respirator, etc.);

• Proper and safe handling, storage and disposal of

the chemical.

> Before using this product, review and verify that all tools to be

used with it have safety equipment installed and are in proper

working order as defined by the tool’s owner’s manual.

> Do not use this product until you have read and are

confident you understand:

• Product Specific Safety Warnings (p. 3);

• Preparing the JIG IT Hinge Mortising System (p. 3);

• Using the Template with the Jig (pp. 3 - 4);

• Hinge Installation Tips (p. 4).

> The user assumes all risk and responsibility for the proper and

safe use of this product and for ensuring product suitability for

the intended application.

> It is the sole responsibility of the purchaser of this product to

ensure that anyone you allow to use this product reads

and complies with all instructions and safety precautions

outlined in this manual prior to use.

> Follow all standard shop safety practices, including:

• Keep children and bystanders away from the tool

operating area;

• Do NOT use power tools in explosive environments, or in

the presence of flammable liquids, fumes or dust;

• TURN OFF AND UNPLUG all power tools BEFORE

making any adjustments or changing accessories;

• Remain alert and use good judgment. Do not use this

product if you are in any way impaired by medications,

alcohol, drugs or fatigue;

• Keep your work area well lit and clean;

• Dress appropriately. Secure loose clothing, remove all

jewelry and tie up long hair before using this product;

• ALWAYS wear safety glasses, hearing protection

and respiratory protection that complies with

NIOSH/OSHA/ANSI safety standards;

• Use dust collection tools and dust face masks to

reduce exposure to dust;

• Use safety equipment such as featherboards, push

sticks and push blocks, etc., when appropriate;

• Maintain proper footing at all times and do not overreach;

• Do NOT force woodworking tools.

> These warnings and instructions do NOT represent the total

of all information available regarding tool safety, use and

technique. Always seek out opportunities to learn more

and improve your skills and knowledge.

Drilling, sawing, sanding or machining wood

products can expose you to wood dust, a substance known

to the State of California to cause cancer. Avoid inhaling

wood dust or use a dust mask or other safeguards for

personal protection. For more information go to

www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury

or property damage.

Notice indicates important or helpful information and/or user tips.

PRODUCT SPECIFIC SAFETY WARNINGS

> To avoid serious injury, keep hands and fingers away from the spinning router bit. Always

maintain awareness of the bit..

> Always make sure that your Butt Hinge Mortise Template

is properly installed in your JIG IT Hinge Mortising

System (58822, sold separately) and that the Hinge

Mortising System is securely clamped to both the lid

and the box before routing. Also make sure that the

assembly will not shift during the routing operation.

> In addition to the warnings provided in these instructions,

the user must comply with all warnings, instructions and

safety guidelines provided by the manufacturer(s) of any

tool or accessories used with this product.

> Turn off and unplug your router before installing the bit or

adjusting the cutter height.

> Always wear safety glasses that comply with OSHA/ANSI

safety standards.

> Wear a dust mask or face covering, use dust collection,

and work in a well-ventilated area.

Preparing the JIG IT Hinge Mortising System

When using the JIG IT Hinge Mortising System with the Butt

Hinge Mortise Templates, it sometimes will be helpful to remove

the clear plastic Fence (identified as Part 2 in the Hinge Mortising

System instructions), depending on how far in from the sides of

the box you will be mounting the hinges. If you are mounting the

hinges somewhat close to the sides, however, the Fence can be

left on and used as a stop for setting up repetitive cuts, and it also

will provide additional clamping surface.

To remove the Fence, remove the Socket-Head Cap Screws and

washers that hold the Fence to the Jig Base and then remove the

Fence. Make sure to store these parts where you will be able to

find them later because you will need them if you use the system

to install quadrant hinges.

Using the Template with the Jig

1. Determine where on the back of the box and lid you want

to install the butt hinges. Clearly mark either the center or

the outer edges of the hinge locations. Accuracy is important,

as you will use these marks to align the template.

> You must have the Rockler JIG IT Hinge Mortising

System (58822, sold separately) to use the Butt Hinge

Mortise Templates. Retrieve the instructions that came

with the jig or download a copy from Rockler.com; you

will need them as a reference.

> Use of this template requires a plunge router,

3/16" diameter straight bit (90000, sold separately) and

a 3/8" O.D. x 5/16"L Guide Bushing Adapter with Lock

Nut (43877 and 63107, each sold separately)

Fence

Front Spacer

Optional Spacer

Check Rockler.com for updates. If you have further questions, please

contact our Technical Support Department at 1-800-260-9663

or support@rockler.com

Make test cuts on scrap to verify the

depth setting on your router. The hinge needs to sit flush or

slightly proud, or the box lid might not close properly.

4Distributed by Rockler Companies, Inc.

4365 Willow Dr. Medina, MN 55340

Rev 10/22

63551 60998 61148 61286 63179

65530 65856 67398 67763 68947

1-800-279-4441

www.rockler.com

2. Choose the correct Butt Hinge Mortise Template for the

hinges you will be using and place it in the opening of the

JIG IT Hinge Mortising System so that the “A” on the

template aligns with the “A” on the jig. Fig. 1.

3. Orient your box and lid as if they’re in the fully open

position and place spacers under the lid so that it is

level with the box.

4. Position the JIG IT Hinge Mortising System on the box and

the lid, with the Front Spacer in between them to ensure that

they’re the correct distance apart. (Depending on how far

in from the end the hinge will be positioned, the Optional

Rear Spacer might also be between box and lid.)

5. Shift the Hinge Mortising System until the etched markings

on the Butt Hinge Mortise Template align with the hinge

location you marked earlier (either centerline or outer

edges). Make sure that the sides of the box and lid are

aligned and ensure that the box and lid are tight against

the underside of the Jig Base. Clamp the lid and box to

the Optional Rear Spacer.

6. Install a 3/16" straight router bit (90000, sold separately) and

a 3/8" O.D. guide bushing and locking nut (43877 and 63107,

sold separately) in a plunge router.

7. Set the bit cutting depth to a hair less than the hinge

thickness. To do this, place the router on the jig with the

bushing in the “A” cutout and — with the router off — slowly

plunge until the bit just makes contact with your box. Engage

the plunge lock. Place a leaf of your hinge under the router’s

depth stop and lower the stop until it contacts the hinge.

8. Double-check that the Template is positioned correctly on

the jig, then make the plunge cut in “A.” Use the bushing

to follow the edges of the cutout, and rout away any material

left in the middle. When finished with the cut, release the

plunge mechanism and allow the bit to stop spinning before

lifting the router from the jig.

9. Test fit a hinge in the mortises you just routed. Fine-tune

the mortises, especially the corners, with a sharp chisel,

if necessary.

10. Repeat the process for any other hinges.

Hinge Installation Tips

To avoid stripping or breaking soft brass hinge-mounting screws,

drill pilot holes and, if possible, tap the holes with a steel screw of

the same size and thread specifications. (Some hinges come with

a steel screw for this purpose.)

If the installed hinge won’t close completely, verify that the

mortise for the lid support (if there is one) is deep enough and

that the hinge is flush or slightly proud of the surface. If you cut

the mortise too deep, small strips of tape or veneer can be used to

shim it up to the proper height.

Fig. 1

“A” letters aligned

Rockler GRP41444 Operating instructions

Rockler GRP41444 Operating instructions

Rockler GRP41444 Operating instructions

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